Metal casting is highly crucial in modern manufacturing. It is technically shaping the whole world. As you know, you can create a wide range of metal parts from this method. High Pressure Die Casting is one of the most popular metal casting methods here.
A typical metal casting method pours molten metal into a mold to create complex and precise shapes. Every industry needs these casting parts for many applications. They may need them for structural support or in their main products.
One popular way to shape metal is through die-casting, and high pressure die casting is one of the most common die-casting methods. This method is what this article is mostly about. You will learn about how they are made, their benefits, and how they can be used. You will also find out how HPDC and LPDC are different.
Overview of High Pressure Die Casting (HPDC)
HPDC stands for High-Pressure Die Casting. As the name suggests, this metal casting method needs high pressure. HPDC casting is suitable for making many metal parts with high tolerances.
In HPDC die casting, molten metal is injected into a steel mold or die at high speeds and pressure. As a result, you can create hundreds of casting parts in less time. The pressure needed here is to ensure that the molten metal fills the detailed feature of the die. Because of this, high-pressure die casting is suitable for high-volume production.
An high pressure die casting machine is made up of several primary components. All of them are very important to the system. You might also find other parts, though. However, these four parts are the most important things in high pressure die casting process. They usually decide how good the casting parts are in the end.
Die Cast Molds
Die-cast molds, or dies, are high pressure die casting machine parts that generally determine the final shape. They have two main halves: stationery and movable. They are usually made from high-strength steel. Making these HPDC die-cast molds is called high pressure die casting tooling. Note that HPDC tooling is crucial for the best quality of metal casting.
Ejector Pins
Ejector Pins are another important components in high pressure die casting mold. They facilitate the removal of the solidified cast from the die. You can find these pins within the movable die half. Once your metal casting is cooled and solidified, you can actuate these pins to remove it. It mainly plays a crucial role in the production cycle.
Cold chamber die casting machine
Cold chamber die casting machine is a most important machinie which has injection system, press system, ejection systems and so on. all of die casting process will be done by this cold chamber die casting machine.
Heating Components
Heating components may include furnaces and heating elements. They typically do not melt the metal but keep the temperature constant. The main goal of this high pressure die casting machine part is to ensure the metal is in liquid form. Note that consistent heating is crucial for the quality and consistency of the final castings.
How DoesHigh Pressure Die Casting Work?
Generally, high pressure die casting works in five steps. Each step is crucial for the final quality of the castings. Therefore, when starting a die-casting process, always inspect the device. Check for any defects or loose screws. Always tune your device to its optimal settings. Check whether the cooling system is properly working or not.
Once you have checked your device correctly, you can proceed to the primary high pressure die casting process. Always wear safety gear, such as gloves, clothes, and glasses.
Step #1 Preparing the Die Cast Mold
You can prepare the high pressure die casting mold in two main steps. First, if it has already been made, check it for defects and contamination before using it. Second, designing the mold is necessary for customized products.
Designing a die-cast mold has several stages. First, you can draw your design using 3D software like SolidWorks, AutoCAD, and more. Ensure you have properly organized the gate runner and mold base when designing it. The cooling system is also a crucial part of this design process. Finally, check the venting & ejection system.
Once you are done with the design, proceed with the draft analysis. You can check its functionality on various simulation software. After testing and quality inspection, you can use the die casting tooling for your final production.
Step #2 Molten Metal Injection
In this HPDC casting process, the machine injects molten metal into the die cavity. Unlike other methods, high-pressure casting uses high pressure and speed for this job, which is why it is called high-pressure die casting.
First, tightly connect the two halves of the die-casting mold. Then, with a button push, the HPDC machine forces the molten metal into the chamber. This pressure technically ensures that the molten metal fills the entire cavity. Once the injection is done, the molten metal is allowed to cool and solidify.
Two primary injection methods are used in the HPDC die-casting system. You can choose the correct method for the job based on your project needs.
Hot Chamber Injection
When your injection mechanism is immersed in the molten metal reservoir, it is called hot chamber injection. When the plunger moves, it draws the molten metal into the chamber and injects it into the die cavity. This type of injection is suitable for metals with low melting points. You may often find this hot chamber die casting machine is used zinc and magnesium alloys.
Cold Chamber Injection
Cold chamber injection, on the other hand, uses a separate melting furnace. You can pour the molten metal using a manual or automated system. In manufacturing, the automatic system is generally operated by a hydraulic plunger. It forces the molten metal to insert into the mold cavity. Cold chamber injection is a common technique for aluminum HPDC casting.
Step #3 Cooling & Solidification
After injection, the molten metal quickly cools within the die cavity. Some factories, like CNM TECH, use controlled cooling. During this time, you must ensure proper solidification.
Note that adequate cooling is mainly necessary to avoid defects. As you know, several defects occur due to inappropriate cooling. Some defects are hot spots, cold shuts or misruns, shrinkage, and porosity.
Cooling channels within the die typically stabilize the temperature. You must ensure these cavities are correctly designed when designing a die-cast mold. At CNM high pressure die casting Factory, our experienced engineers always test these cooling systems. Thus, our metal casting has almost zero defects.
Step #4 Ejection
Once the metal alloy part has cooled and solidified within the die, eject it using the ejector pins. Carefully do this step to avoid any external damage. The ejector pins usually facilitate this removal process. They are on the movable part of the die-cast mold.
Step #5 Trimming & Finishing
After removing the metal part, you may find some extra material on the body. You may need some additional finishing processes to get it in good shape. You can perform trimming, grinding, or other surface treatment methods.
The trimming method usually removes excess material from the metal part. It can be manual or automated. However, a smooth surface may need grinding, sanding, or machining. These methods can help you achieve the desired dimensions.
If you need more finishing, you can use different aluminum surface treatments. There are many ways to do this. These techniques can help your HPDC casting parts be more robust and less likely to rust. The most common methods are black or clear anodized aluminum, painting, powder coating, e-coating, and more.
After all this, your HPDC casting parts may need testing for certifications. Note that certifications create customer trust and reliability in real applications.
What are the Key Features of High-Pressure Die Casting?
In the previous section, we discussed the HPDC die-casting process in detail. As you know, in the HPDC casting process, the machine pours molten metal into the die or mold cavity at high pressure and speed. This technically provides several advantages. Let’s check them one by one.
Feature #1 High Precision Metal Parts
One of the best benefits of the HPDC casting process is the precision. Using this tech, you can achieve very high accuracy. According to experts from various industries, this tolerance ranges from ± 0.016mm to ± 0.12mm.
Feature #2 Work with More Complex Designs
HPDC die-casting process also allows you to work with more complex designs. As you know, high-pressure forces molten metal to fill a detailed mold cavity. This means that these molten metals can reach every detail of the design. Most aluminum intricate metal parts are made through the HPDC casting process.
Feature #3 Better Surface Finish
The HPDC casting process also produces a better surface finish. The molten metal fills every corner of the mold cavity under high pressure. Because of this pressure, the density of the metal part also remains the same. Because of this, the surface gets a better result after it cools.
Feature #4 Increased Productivity
The high-pressure die-casting process works very fast. In some manufacturing, this process is fully automated. However, whether manual or automated, it is still faster than other methods. Because of this, you can make hundreds of metal parts in less time. This increases your productivity and reduces costs.
Feature #5 Work with Thinner Wall Products
Again, the high-pressure molten metal fills every corner of the mold cavity. This technology allows you to work with thinner-walled products. Some typical examples are engine components, housings, and heat sinks.
Feature #6 Better Quality
High-pressure casting parts are famous for their high quality and consistency. The controlled process parameters and precise molds always give you uniform castings. This consistent quality ensures better mechanical properties. Specifically, the casting metal parts can have more strength and durability.
Feature #7 Durable Dies
Finally, the tools used in HPDC casting are usually made of good steel. These molds or dies can easily handle high pressure repeatedly. Overall, durable dies eliminate the need for frequent replacement. Once created, they can make thousands of metal parts repeatedly, reducing production costs.
What Materials Are Compatible with High-Pressure Die Casting?
Although HPDC casting can work with most types of metals, it is uncommon. The most common materials people usually use are aluminum, magnesium, and zinc. Ferrous metals are especially not ideal because they are more prone to rust.
Aluminum
Aluminum is one of the most used materials in HPDC casting. This metal has a high strength-to-weight ratio and is 100% recyclable. Aluminum is also famous for its excellent corrosion resistance. Compared to its weight, aluminum can withstand large loads. You may find its use in construction, automotive, and aerospace.
Moreover, aluminum has good thermal and electrical conductivity. Thus, it is often used in house appliances and various electrical gadgets.
Magnesium
Magnesium is also a lightweight metal used in HPDC casting. Although it is not as famous as aluminum, magnesium is also prevalent in many applications. It is especially suitable for use where weight reduction is crucial. You can use it in vehicle seats, trolleys, laptops, or cameras.
Magnesium is strong and easy to machine. You can give it a complex shape and intricate details. In addition, you can use it for various dampening applications.
Zinc
Zinc alloys are another famous material used in high pressure die casting. They are typically renowned for their excellent fluidity and low melting point. However, zinc alloys have better dimensional stability. You can create complex shapes with thin walls.
Zinc alloys are also resistant to impact and suitable for long-lasting performance jobs. They are mainly used in decorations, but other applications include locking tools, gears, and various car parts.
The Use of HPDC Casting in Various Industries
HPDC die-casting parts are prevalent in many industries. They are versatile, and people use them in many applications. Since HPDC offers several features, we can find its use in the following sectors:
Automotive Industry
Automotive is a common place for HPDC castings. Engine blocks, transmission gears, gearbox housings, and other aluminum parts are typical. Like car seats, high-pressure casting can also be used for various structural supports.
As you know, HPDC casting makes strong and light parts, which is very important in the car industry.
Consumer electronics
Another popular place for HPDC casting parts is consumer electronics. You may find these castings in smartphones, laptops, cameras, and other electronic devices.
As you know, the high-pressure casting process ensures these components meet tight tolerances. Other finishing methods can achieve aesthetic appeal.
Medical Equipment
It is crucial in the medical field to use light and precise materials. HPDC casting lets you make metal parts that are of high quality and meet tight tolerances.
Various diagnostic devices and surgical equipment also use HPDC castings. Moreover, various device housings are also made of high-pressure castings.
Defense Industry
The need for lightweight parts is critical in defense. They make military trucks more mobile, faster, and better at using fuel. Because of this, operations are more efficient and easier to move and set up.
Most importantly, lightweight materials provide tactical benefits in various combats. Weapons, military vehicles, and communication gadgets are all examples.
Aerospace Industry
This industry mainly relies on HPDC casting parts. Most airplanes need strong and light parts. Engine parts, housings, and brackets are common HPDC airplane items.
What is Aluminum HPDC Casting?
Aluminum HPDC casting is the most common high-pressure die casting. The process is all the same, but the material is aluminum. However, HPDC aluminum is suitable for various reasons.
HPDC aluminum parts are trendy because they are precise. Their high-quality finish also makes them ideal for many jobs. As discussed in the previous section, people use these parts in many fields.
Also, aluminum HPDC castings are strong and last a long time. They are strong for how light they are compared to their strength. So, you can use them in many places where support is needed, like car seats.
As you know, aluminum HPDC casting works with high pressure and speed. Thus, it can produce hundreds of parts in less time. Therefore, high-pressure aluminum die casting is cheap per unit.
HPDC aluminum alloys are also prevalent in a variety of structural applications. Some of the structural parts of your car are made of HPDC aluminum alloys, as well as the engine blocks and chassis.
Common aluminum alloys used in HPDC include A380, A383, and A360. A380 or A383 are suitable for strength and corrosion resistance. On the other hand, the A360 offers excellent pressure tightness. These alloys have unique benefits in HPDC casting processes.
High-Pressure Die Casting vs. low-pressure Die Casting (HPDC vs LPDC)
Both high-pressure die casting and low-pressure die casting are prevalent in real-world applications. However, each has its unique benefits and uses. We have already learned so much about HPDC. Let’s compare HPDC die casting with LPDC die casting in the following table.
| Feature | High-pressure Die Casting (HPDC) | Low-Pressure Die Casting (LPDC) |
| Process | Molten metal is injected into a die at high pressure and speed. | Molten metal is forced into a die by low pressure and speed. |
| Pressure range | High (1500 to 25000 psi) | Low (2-= to 15 psi) |
| Die Construction | Steel dies are used, often complex, multi-part | Steel or iron dies, typically simpler and less complex |
| Speed | Very fast, suitable for high-volume production | Slower compared to HPDC, leading to longer cycle times |
| Surface finish | Excellent with smooth surface and fine details | Good, but generally not as tight as HPDC |
| Accuracy | High, with tight tolerances, usually ranges between ± 0.016mm and ± 0.12mm. | High, not as accurate as HPDC |
| Complexities | Can produce highly complex parts with thin walls | Suitable for moderate complex parts with thicker walls |
| Tooling cost | Higher initial cost due to complex dies | Lower initial cost due to simpler dies |
| Cooling rate | Fast cooling | Slower cooling rate |
| Typical Alloys | Mostly aluminum, magnesium, and zinc alloys | Mostly aluminum alloys with some use of magnesium and copper |
CNM TECH – Custom HPDC Casting Services
CNM TECH is high pressure die casting company in China, it is founded in 1999 and backed by a family that has 18 years of experience in high pressure die casting manufacturing business. This factory generally does cast and different kinds of machining. You can get OEM metal parts, custom metal parts, and other metal parts. One of the main things they do is high-pressure die casting (HPDC).
We offer custom metal parts solutions. Whether you are looking for OEM metal parts, custom HPDC castings, small- to medium-large volume aluminium die casting, magnesium die casting, zinc die casting, or prototypes, CNM TECH is the factory you need. We have the latest machinery and testing equipment and offer various certifications. As a result, we are capable of meeting diverse client needs. Overall, CNM TECH provides reliable and affordable casting services.
With our ISO 9001 certified production and quality control systems, we provide global customers with the highest quality pressure die casting services. In addition, we offer secondary operations and light mechanical assemblies. such as surface finish including powder coating, nodizing, e-coasting, painting etc. CNM TECH. is one of the best internationally known high pressure die casting companies in the world. Our experienced and English-speaking engineers and our worldwide sales staff provide excellent pre-sale and production support.
Services We offer
High pressure die Casting parts and molds in aluminum, magnesium and zinc alloy
CNC machining – vertical, horizontal, turning, 5-axis
Prototyping machining
Powder Coating
Liquid Coating
EMI – RFI Shielding
Plating – chrome, copper, zinc, nickel, tin, gold
Anodizing, Electrical Coating, Chromating/Non-chromating
Heat Treatment, Passivation, Tumbling
Graphics
Pad Printing
Bead Blasting
Light Mechanical Assembly, including stud and helicoil inserts, O-ring, gasket
Laser Cutting and Engraving
Etching
If you need any supporting in die casting parts you are welcome to contact us, we would happy to support, no matter you need technical supporting or price for your project.
FAQs
Can steel be a pressure die-cast?
You can pressure die-cast stainless steel, but it rarely happens. Aluminum, magnesium, and zinc are popular metals that can be used for high-pressure die casting (HPDC). Steel has a high melting point. Simply put, its qualities make it unsuitable for HPDC casting. You can still do the pressure die-cast, but it might cost more than you thought to make.
What products are made by high-pressure die casting?
You can create a variety of products using HPDC technology. As you know, high-pressure die casting uses high pressure and speed to make each component. As a result, you can create better quality and more complex designs. Some HPDC castings are engine blocks, surgical equipment, laptops, and more.
What is casting pressure in HPDC?
Casting pressure is usually the force used in the HPDC casting process. This pressure usually forces the molten metal to reach every corner of the mold cavity. However, it typically ranges from 1500 to 2500 psi. The exact pressure depends on the type of design and metals.
What grade of aluminum is used for high-pressure die casting?
The most common grade of aluminum used for HPDC casting is A380. The A380 is the most common alloy in die casting because it is strong and easy to work with. This alloy usually has more fluidity than A360. Thus, A380 is more suitable than A360 for the high-pressure die-casting process. Besides, the A380 offers excellent dimensional stability and conductivity.
Summary
High-pressure die casting (HPDC) creates metal parts at high pressure and speed. The pressure usually ranges from 1500 psi to 2500 psi. HPDC casting is a fast and efficient method for making complex shapes.
Aluminum HPDC casting is the most common. A380 aluminum alloy is more prevalent in this case. Aluminum is strong, lightweight, and offers excellent corrosion resistance. Thus, it is often used in many applications.
If you have any questions, feel free to contact us today. We offer all types of casting and CNC machining services, and our team of experts is always happy to assist you.